Compost curing and odor control system

ABSTRACT

A compost curing and odor control system in which biofilters are disposed in overlying relation to the compost curing area the floors of both the biofilters and curing area consist of a series of elongated planks of generally trapezoidal cross sectional configuration placed in abutting relation with the longer parallel sides of the trapezoid lying in the plane of the floor and forming between them a narrow slit through which air is passed by means of an underlying air plenum in pneumatic communication.

FIELD OF THE INVENTION

This invention relates to a method and apparatus for curing compost andfor deodorizing effluent gases emanating from the curing process. Morespecifically the invention is directed to a unique air-floor design andmethod of operation which improves and accelerates both the curing anddeodorizing phases of the process as well as providing a unique watermanagement system.

BACKGROUND OF THE INVENTION

Prior art systems for curing compost commonly utilize a concrete floorcontaining rectangular trenches in which is laid perforated pipe theends of which are supplied air from a common plenum. The pipes areoverlaid with a metal or plastic grating or gravel distribution systemto permit front end loaders to traverse the floor to turn the compostperiodically. A major problem of such systems is non-uniform airdistribution resulting in unreliable curing of the compost. Anotherproblem normally encountered in the use of such systems is clogging ofthe floor air vents necessitating shut down of the system until thevents have been cleared. A concomitant problem that results as the ventsbecome clogged is that pressure required to maintain desired air flowincreases. Consequently, blowers of increased capacity are needed toinsure optimum curing conditions to offset the effects of variable backpressure caused by clogging of the air vents. The above problems resultin unproductive down time with attendant increase in the cost ofoperation. The present invention ameliorates these problems. It is alsoto be noted that through use of the subject apparatus and method ofoperation the maintenance and effectiveness of the curing process ismaterially enhanced. The air channels are more easily accessed andcleaned and the overall costs of the curing system substantiallyreduced. Another aspect of the invention is the unique positioning ofthe system elements. Important factors in the siting of compost curingsystems are the proximity of the system to populated areas and therequired land area needed for operations. By positioning the biofiltersin overlying relation to the curing floor as herein taught by applicanttwo major objectives are achieved. First, the area required foroperations is reduced and secondly the filtering system is positioned toinsure that effluents from the biofilter are emitted at higherelevations insuring that there is greater dispersion of effluent uponits release into the atmosphere. There is also provided a novel systemfor effecting dispersion of effluents during atmospheric inversions andfor retaining and conserving water.

SUMMARY OF THE INVENTION

Central to one phase of the invention is the provision of a unique floordesign. The aeration bay is comprised of a series of structural concreteelements each having a generally trapezoidal cross section. The elementsare placed in abutting relation with the longer parallel side of thetrapezoid lying in the plane of the upper surface of the air-floor. Theend of each element rests on a concrete beam. This arrangement providesfor a very thin point of contact between adjacent elements. To create anarrow slit through which air can pass a thin rotary saw blade or rakeis passed along the point of contact. The slit is narrow enough toprevent compost stacked on the floor from falling through the slits.Underlying the floor are a series of air plenums which are supplied airfrom a common manifold. Such an arrangement provides uniformdistribution of air throughout the system and is substantially clogfree. The system is easily maintained without interrupting the curingprocess. It has been discovered that by employing a similar type offloor construction as an element of a biofiltering system similaradvantages accrue. Additionally, through use of vertical stacking of thecuring and air filtering components, a more economic and efficaciouscuring and air purification system is achieved. To optimize operation ofthe biological systems the air plenums are converted to oxidationditches or ponds by partially filling the plenum with collected waterand conveying leachate from the biofiltering and compost curing units tothe aeration plenums. This procedure inoculates the water with microbialcultures which are then selectively sprayed on both the compost pilesundergoing curing and the biofilter media. Additionally, by using theroof as a collection device for rain water and plenums as water storagesites a unique water management system is achieved.

BRIEF DESCRIPTION OF THE DRAWINGS

The above described and other features of the invention will be morefully understood by reference to the detailed discussion of theinvention hereinafter set forth taken in conjunction with theaccompanying drawings, in which;

FIG. 1 is a side elevation of an aeration curing bay embodying oneaspect of the present invention;

FIGS. 2A and 2B depict cross-sectional details of alternate floor plankdesigns;

FIG. 3 illustrates a compost aeration and odor control system using rooftop biofilters;

FIG. 4 is a side elevation showing details of the biofiltering system;

FIG. 5 is a diagrammatic plan view of the air plenum distributionnetwork;

FIG. 6 depicts a biofilter exhaust system using wind machines; and

FIG. 7 is an isometric view showing the water retention and conservationsystem and the microbial reinoculation arrangement achieved throughpractice of the present invention.

DETAILED DESCRIPTION

For purposes of illustrating the invention, there is shown in thedrawings a form which is presently preferred; it being understood,however, that this invention is not limited to the precise arrangementsand instrumentalities shown.

Current state-of-the-art systems for achieving composting of solid wasteand sewage sludge employ one or more multi-stage, horizontally disposeddigesters in which materials being treated undergo staged microbialdecomposition. The digester comprises a tube-like structure divided intotwo or more compartments or stages. During material processing the tubeis rotated while air is circulated through the digester at controlledrates under predetermined conditions in a flow direction counter to thematerial flow. The climate in each stage is maintained to achieve theoptimum development of the type and species of microorganism predominantin that stage. Typical of such systems and methodology of operation arethose set out and described in U.S. Pat. Nos. 3,245,759 and 3,138,447,assigned to the assignee of the present invention, the teachings ofwhich are hereby incorporated by reference.

In a composting system utilizing a multi stage digester for theco-composting of municipal solid waste and sewage sludge the typicalresidence time in the digester is normally three days. Upon removal fromthe digester the material is comprised of partially cured compost andnondegradeables. The partially cured or rough compost is conveyed to anarea in which further composting or curing is carried out. For purposesof this invention this phase of further processing of the partiallycured compost will be referred to generically as curing. The term curingarea as used herein shall mean an area in which partially cured compostis stabilized into a humus-like material. The curing stage of thecomposting process is an important and essential phase of the overallprocess. It is to this phase of the process, and the subsequenttreatment of the processing air prior to its release to the atmosphere,that the present invention is primarily directed. However, it should beunderstood that teachings of this invention have broader applicationthan the specific embodiments herein described and can be employed inthe treatment of compostable material which has not undergone previousprocessing or in the deodorizing and treatment of gases from any of anumber of different sources.

Referring now to the drawings and more particularly to FIG. 1 thereof,there is shown in cross sectional elevation an air floor and air supplysystem comprising a preferred form of aeration bay incorporating oneaspect of the present invention. As seen in that Figure the air floor 10is comprised of a series of planks 12 made of concrete. Underlying thefloor is an air plenum 14 made of concrete walls and underlain with highdensity polyethylene thirty to one hundred mills in thickness. To permiteasy access to the plenum for maintenance purposes it is at least threefeet in depth. The plenum underlies a curing area 16 which in theillustrated embodiment is twenty feet in width, (running perpendicularto the plane of the paper) and sixty feet long, a portion 17 of the areais kept clear of compost to provide a path for return of the compostturning mechanism 18 to its starting position. A preferred constructionof the planks making up the air floor is shown in cross section in FIG.2A. The FIG. 2A plank is 8" in thickness from top to bottom and has atrapezoidal cross section and a rectangular lower section. The topsurface 20 is 10" to 12" wide and the bottom surface 21 is 8" to 10" inwidth. The concrete is set up around reinforcing steel 24 to provide therequisite structural strength. In constructing the air floor the planksare laid side by side in abutting relation as shown in FIG. 2A. At theircontact point a slit 26, about 1/16 inch in width is formed using a sawor raking tool. This procedure is used to insure a controlled anduniform width of air slit. This unique construction insures uniform airdistribution, an essential to efficient and effective curing whileretaining the required structural strength to support compost stackedsix to ten feet high on the air floor. Furthermore, these structuralelements have sufficient strength to support a rubber-tired front-endloader when and if needed to move compost on the air floor. Analternative plank design capable of achieving the objective of uniformair distribution and structural strength is also available. In thisembodiment the core 27 serves as an air conduit in communication withslits 28.

An aeration channel comprised of 30 curing bays 15 feet wide and 60 feetin depth in which compost is stacked 10 feet high can hold approximately5000 tons of compost. Compost 30 to be cured is stacked on the curingfloor. As seen in FIGS. 1 and 5 the air plenums 14 of the individualbays are each supplied air via 8" diameter pvc ducts 32 which in turnare connected to a 24" diameter pvc manifold 34 supplied air by fans 36(FIG. 5). The requite temperature for curing is between 55 to 65 C.degrees. To maintain the process within these parameters of operationeach feeder line 32 is provided with a computer controlled air damper 38to modulate air flow. Temperatures within each bay are monitored bymeans of temperature probes 40 located at strategic locations within thecuring bay. To produce a desired air flow throughout each curing channelthree fans are provided, one located at the middle and one at either endof the channel. It has been found that fans each having a capacity of12,000 cfm provide proper conditions for aerobic biologicaldecomposition given the above operating parameters. The diagrammaticplan view shown in FIG. 5 depicts the above arrangement. The entiresystem is under control of computer 42.

Each compost aeration bay utilizes a compost turning mechanism such asclaimed and described in U.S. patent application entitled Compost CuringSystem, Ser. No. 08/235,970 filed May 5, 1994, assigned to the assigneeof the present invention, the teachings of which are hereby incorporatedby reference. As described in that application, the turning mechanism 18(FIG. 1) is movably suspended in overhanging relation to the compostpile by means of a bridge crane mounted on a truss-like or beamstructure 44. The crane is mounted for movement from front to back alongthe length of the pile and the turning mechanism is attached to acarrier 48 mounted for movement along the truss from side to side acrossthe pile. The compost turner itself is of generally V-shapedconfiguration one leg of which is comprised of a paired set of counterrotating ribbon augers 50 and the opposite leg consists of a associatedconveyor system (not shown). To permit use of the turner with compostpiles of varying heights and to permit variable spacing between turnedand unturned sections of a compost pile, the augers and conveyor systemcan be made pivotly adjustable relative to the support structure and toeach other. Compost which has undergone curing in an aeration bay forapproximately four weeks is moved out of the bay by the automaticturning apparatus.

Referring now to FIG. 3 there is shown in cross sectional elevation abiofilter constructed in accordance with the present invention. Thefloor 52 is identical in construction to that used in the aerationcuring floor shown in FIG. 1. It also has a plenum 54 similar to thatused in the curing bay which underlies the biofilter floor. An alternatedesign would entail an air floor using planks as shown in FIG. 2B whichwould obviate the need for an air plenum. The plenum receives effluentgases emanating from the curing floor through ductwork 56 powered by asuction fan 58. The gases are passed through the biofilters to effecttheir deodorization. To insure effective deodorizing of the effluentgases the filtering media 60 is automatically and periodically turnedand fluffed by turning machine 62. The turning machine is ofconventional construction and comprises a series of paddles 64 mountedon a common shaft as seen in FIG. 4. The turner is carried by a dolly(not shown) moving on rails 66. It will be understood that biofilters ofthe type illustrated have wide application to the processing ofeffluents generally and are not restricted to the deodorizing of gasesfrom the curing of compost derived from the co-composting of municipalsolid waste and sewage sludge. Using an automatic turning machine inconjunction with this configuration allows for a continual, thoughperiodic movement, of the biofilter media through the biofilterchannels. This automatic turning of biofilter media allows forcontinuously restored media and provides an assured consistency ofbiofilter back pressure, media porosity and filtering capacity.

During traverse of a channel, the filtering media is moved between 6 to8 feet toward the discharge end. At the end of each traverse the turningmachine is moved onto a automatic transfer dolly (not shown) whichpositions it at the next channel to repeat the next cycle. The length ofeach channel is determined by the air treatment requirements of aparticular application. Turning machines of this type are well known inthe prior art.

As cured compost moves out of the curing bay it is screened to a finegradation. That portion which fails to pass through the screen is usedto augment the biofiltering media 60 and is introduced into thebiofiltering system at a location overlying the point at which compostis discharged from the aeration curing bay. By this method of operationthe rawest emissions from the curing bay are filtered by the most matureand finely divided filtering media thereby achieving more effectivefiltration of the effluent gases.

The biofilter media is designed to move counter to the movement ofcompost on the aeration floor and is moved by turning apparatus 62 alongand through the filtering bed over a period of approximately twelveweeks. At the discharge point of the biofiltering system the spent mediais removed, the man made inerts are screened out, and balancereintroduced into the aeration curing cycle. By this technique thequantity of material ultimately sent to land fill is greatly reduced.

In instances in which atmospheric air temperatures are layered, acondition known as thermal inversion occurs, where surface air is helddown along with its pollutants. To counteract this problem, the novelarrangement shown in FIG. 6 is employed utilizing a wind machine 70. Toincrease the effectiveness of such an arrangement a venturi-shapedcanopy 72 can be used to channel the air as shown in phantom in thatFigure. The wind machine is capable of dispersing the filtered air atelevations as high as 700 feet, well above normal inversion levels,resulting in an environmentally acceptable operation under the mostadverse conditions. To achieve the desired result, each 10,000 sq. ft.of biofilter surface has disposed over it an 18 ft diameter wind machinehaving an 850,000 cu.ft/min. output. The fan effects a ten to onedilution at the fan blade and pushes diluted air through the inversionlayer to an altitude of about 700 feet. Wind velocities obtained in thesystem are in the 40 to 50 mile per hour range at the face of the fan.To achieve even higher velocities and efficiencies a venturiconstruction can be employed. Dispersion of effluents using roof topbiofilters is normally satisfactory until there is an atmospherictemperature inversion. At this point the fans can be phased into usediluting the odor and pushing it through the inversion layer for furtherdilution and dispersion. A shroud or fabric enclosure over the biofilterarea can be used to insure capture of all effluent gases.

A still further feature of the invention, as depicted in FIG. 7, is theprovision of a water management system which enhances and acceleratesthe curing process, reduces or eliminates liquid effluents from thecomposting system and the need to buy water from off site, conserveswater and also enables the operation to meet local storm water retentionrequirements. Leachate from the biofilters and the compost undergoingcuring on the aeration floor is collected and stored within theunderlying plenums. By this process, leachate which otherwise mightmigrate into the ground water, is collected and reintroduced into thecomposting process. Leachate from the biofiltering media is piped byductwork 74 to the aeration bay plenums 14 where it is mixed with rainwater collected from the roof 76 to form an oxidation pond usingmicrobial cultures for treatment and purification. The cultures now insolution form are conveyed by pump 78, piping 80 and valving 82 to sprayheads 84 to irrigate both compost undergoing curing and the biofilteringmedia. This procedure aids and accelerates the ongoing biologicalprocess. Water 86 within the plenums is warmed by process air blown intothe plenums via ductwork 88. Nozzles 90 are employed to agitate andcause movement of water around a partition 91 centrally disposed withinthe plenum. This action both heats and agitates the water to enhancemicrobial growth and prevent water stagnation.

As noted above, the plenums underlying the aeration curing floor act asoxidation ditches or ponds and serve as incubating chambers for thegrowth of microbial cultures, which can then be used to reinoculate thebiofilter media and compost. Air is passed through and is blown by fans(not shown) over the leachate solution within the plenum to both heatthe solution and induce a mild current. The air nozzle 90 within theplenum is flexibly supported on a float 93 carried on the surface of thesolution. Microbial cultures grown in the oxidation ditch are sprayedover the compost and filtering media, as needed, through use of sprayheads 84. The roof or deck 76 is provided with a walled section 96 atboth ends which along with walls 98 on which the biofilter turningapparatus rides form a water collection area. To insure the roofs waterretention capabilities it can be covered by a waterproof single membraneroofing material such as high density polyethylene.

Rain water falling on the roof may be either directed to storm waterfacilities or diverted by means of valving 100 and associated plumbing102, schematically illustrated in FIG. 7, to plenums 14 underlying theaeration floor. An assembly as previously described comprised of 30aeration bays each having a plenum 15' wide by 60' long and 3-6 feet indepth can hold over a million gallons of water. In situations in whichthere is an excess of rain water as might occur in Florida during thesummer months water can be diverted by valving 104 off-site.

In summary, use of the novel floor design herein described in both theaeration and biofilter systems provides uniform and predictable air flowdistribution, a necessary and heretofore unattainable objective in theefficient and economical curing and deodorizing of compost.Additionally, the novel positioning of the biofilters in overlyingrelation to the aeration floor conserves space and results in greaterdispersion of air emissions into the atmosphere. This direct coupledarrangement allows for the elimination of all air flow ducts thuscutting head losses in such piping and cutting the costs of biofilteroperations. This arrangement also conserves aeration floor heat, afactor especially important in cold climates to keep biofilter mediafrom freezing. Finally, by utilizing the roof structure and air floorplenums as reservoirs and oxidation ponds a novel water management andcompost and biofilter media reinoculation system is provided.

It will be understood that structural and dimensional modificationsdiffering from those described and illustrated will be required to meetvarying circumstances and that the present invention may be embodied inother specific forms without departing from the spirit or essentialattributes thereof and, accordingly, reference should be made to theappended claims rather than to the foregoing specifications asindicating the scope of the invention.

I claim:
 1. A compost curing system comprising; a floor for deposit ofpartially cured compost; said floor consisting of a plurality oflongitudinally extended polyhedron shaped planks laid side by sidehaving a generally trapezoidal cross sectional configuration the longerparallel side of which lies in the plane of the floor; said planks beingspaced from each other to form slits approximately 1/16 inch in widthand forming a series of generally triangular shaped open trenchesunderlying the floor's upper surface; an air plenum underlying the floorin communication with said trenches and wherein said floor forms anupper surface of said plenum; and means for delivering pressurized airto said plenum to cause dispersion of air through said trenches.
 2. Acompost curing system as set forth in claim 1 comprising partially curedcompost deposited on said curing floor, and means for automatically andperiodically turning said compost.
 3. A compost curing system as setforth in claim 2 including means enclosing said system.
 4. A compostcuring system as set forth in claim 3 wherein means is provided forcollecting gases emanating from compost deposited on the curing floorand dispersing said gases through a biofilter disposed in overlyingrelation to the curing floor.
 5. A compost curing system as set forth inclaim 4 wherein said biofilter has a floor construction comprising aplurality of longitudinally extended polyhedron shaped planks laid sideby side having a generally trapezoidal cross-sectional configuration thelonger parallel side of which lies in the plane of the floor; saidplanks being spaced from each other to form slits approximately 1/16inch in width and forming a series of generally triangular shaped opentrenches underlying said floor.
 6. A compost curing system as set forthin claim 5 including means for periodically and automatically turningthe biofilter media.
 7. A compost curing system as set forth in claim 6including a green house enclosing both said biofilter and turning meansand having valve means for releasing to the atmosphere gases emanatingfrom the biofilter.
 8. A compost curing system as set forth in claim 7including means overlying said biofilter for drawing off gases emanatingfrom the biofilter and for dispersing same at elevated altitudes in theatmosphere.
 9. A compost curing system as set forth in claim 8 whereinsaid means for drawing off gases comprises a wind machine.
 10. A compostcuring system as set forth in claim 9 including a canopy disposed oversaid biofilter and interposed between said biofilter and said windmachine through which gases emanating from said biofilter are caused topass.
 11. A compost curing system as set forth in claim 9 wherein saidcanopy overlies said wind machine and is in the shape of a venturi. 12.A compost curing system comprising; a curing floor for deposit ofpartially cured compost, said floor consisting of a plurality oflongitudinally extending polyhedron shaped planks having a generallytrapezoidal cross-sectional configuration, the longer parallel sides ofwhich collectively form the floors upper surface and adjacent slabsforming between them a plurality of open trenches of generallytriangular configuration; a first air plenum underlying said floor incommunication with said trenches and wherein said flooring forms anupper surface of said plenum; means for delivering pressurized air tosaid first air plenum; means for collecting effluent emanating from thecuring floor; one or more biofilters disposed in overlying relation tothe curing floor, said biofilters having a floor construction comprisinga plurality of longitudinally extended polyhedron shaped planks laidside by side having a generally trapezoidal cross-sectionalconfiguration the longer parallel side of which lies in the plane of thefloor; said planks being spaced from each other to form slitsapproximately 1/16 inch in width and forming a series of generallytriangular shaped open trenches underlying said floor; a second airplenum underlying the biofilter floor wherein said flooring forms anupper surface of said plenum; means for collecting effluent emanatingfrom the curing floor and for delivering same to said second air plenum;means for automatically and periodically turning the compost undergoingcuring; and means for automatically and periodically turning thebiofilter media.
 13. A compost curing system as set forth in claim 12including a greenhouse enclosing said biofilter and its turning meansand including means for venting gaseous effluent from said greenhouse tothe atmosphere.
 14. A compost curing system as set forth in claim 12wherein said biofilters are disposed on a deck, sections of which areexposed to the atmosphere for collection of rain water.
 15. A compostcuring system as set forth in claim 14 including means for controllablefunneling predetermined quantities of collected rain water to said firstair plenum.
 16. A compost curing system as set forth in claim 15 whereinleachate runoff from said biofilters collected in said second airplenums is selectively funneled to said first air plenums.
 17. A compostcuring system as set forth in claim 16 including means for selectivelyspraying leachate-inoculated water from said first air plenums onto bothcompost undergoing curing and the biofilter media.
 18. The method ofcuring compost which comprises stacking compost to be cured on anaeration floor comprised of a series of elongated elements oftrapezoidal cross-section the longer parallel sides of which form theaeration floor; placing said elements in side-by-side relation; forminga series of longitudinally extending narrow slits between adjacent floorelements; providing a plenum underlying said aeration floorcommunicating with said slits and wherein said flooring forms an uppersurface of said plenum; and providing a means for delivering air to saidplenum for distribution through said slits and overlying compost. 19.The method of claim 18 including the step of collecting in said plenumleachate runoff from compost being cured; incubating within the plenumthe microbial content of the leachate and inoculating the compostundergoing curing with incubated microbial culture.
 20. A compost curingsystem comprising an air floor containing a plurality of spacedair-passage slits narrow at their top and increasing in width withincreasing depth; an air plenum underlying said slits wherein said floorforms an upper surface of said plenum; and means for delivering air tosaid plenum.